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Ermakova N. V.,
Candidate of Chemical Sciences, docent, Kursk State University, Kursk
Andreeva, V.Yu.
Candidate of Philological Sciences, docent, Southwest State University, Kursk POSSIBILITIES OF PROCESSING OF SECONDARY RAW MATERIALS
ABSTRACT
Secondary raw materials and waste on most of the sugar factories practically do not bring profit. However, considering the significant amount of waste and the fact that the price of some products potentially recoverable from beet chips, may substantially exceed the value of sugar, the real economy requires a fundamentally different approach to the functioning of the sugar industry. Options of processing and use of by-products of beet sugar manufacture are considered in the article.
Keywords: production wastes, secondary raw materials, pulp, filtration sludge, molasses, suspension of transport and washing sludge
In the last few years, waste-free production, i.e. the most rational and complex use of raw materials, energy and secondary resources, is paid particular attention. It is desirable that the system be closed, then the production becomes highly environment-oriented.
In sugar production the volume of raw and auxiliary materials several times exceeds the amount of the finished product. The share of processing of secondary raw resources is too low, and the development of environmentally sound methods of disposal and treatment of waste is solved mainly by the sugar factories and their own finances.
Valuable (in addition to sugar) components of the raw materials and the processing of by-products, in most cases, will only be considered as components, creating additional problems of primary production. Secondary raw materials and waste on most of the sugar factories practically do not bring profit. However, considering the significant amount of waste and the fact that the price of some products potentially recoverable from beet chips, may substantially exceed the value of sugar, the real economy requires a fundamentally different approach to the functioning of the sugar industry. It coincides with environmental demands.
By-products of production include sugar beet, molasses, filtration sludge and slurry transport-washing sludge that are the most valuable and can be manufactured as secondary raw materials. Annually sugar factories in Russia receive up to 24 million tons of secondary resources and most of them - up to 21 million tons of beet-pulp.
The presence of a variety of valuable components in pulp can be used in various sectors of livestock and industry. For example, in the production of pectin food (dry pectin powder), which is used in the confectionery
industry instead of apple pectin and other gelling substances. Pectin concentrates are in demand in medicine (low- etherified pectin is used in the treatment of gastrointestinal diseases with children, as a part of pectin-gelatin complex with additives of physiologically active substances for the treatment of open wounds and burns; as a hemostatic means; to neutralize the impact of heavy metals and radionuclides in the human body), in pharmacology, cosmetics, canning, confectionery, dairy, bakery industries.
Dietary fiber derived from sugar beet pulp promote the excretion of some metabolites of food and polluting substances, regulation of physiological, biochemical processes in the digestive organs and are therefore used for production of biologically active additives.
Livestock fodder (for the large-horned animals, pigs, sheep, and goats, rabbits, fur animals and poultry) is about half of the pulp in different forms: sour (located in the factory store more than 3 days), ammoniated (gained from the implementation of the ammonia water in the sour pulp, which helps to eliminate the acid and enrich in protein), canned (subjected to simple ensilaging, i.e. compacting, or ensilaging with the addition of acids as preservatives and chemicals, making it rich in nutrients), dried (in loose, granular or briquette forms).
When granulating sugar beet pulp, molasses can be added to it, thereby increasing the strength of its pellets and forage value.
Despite the unique properties about 30 - 40 % of pulp until now remained unclaimed, and drying mills as well as granulation pulps already installed on many sugar factories stood idle.
The second half of 2011 is characterized by the burst of the elaboration of the beet pulp in connection
with the record crop of sugar beet. In 2012, experts predict approximately the same level of sugar production [5].
Pulp export grew by 45% to 455 thousand tons in 2011, and in 2012 the same or slightly greater volume is expected [8].
With the development of the meat and dairy industries the share of the pulp used in a fresh kind on cattle feed will increase.
Molasses is the main raw material in the production of bakery yeasts (tons of molasses give about 800 kg of yeast), used in the manufacture of fertilizers, lysine, food acids, for dulcifying liqueurs and spirits, for the enrichment of the dried food and giving strength to the granulated sugar beet pulp, as well as in alcohol production plants located in the zone of cultivation and processing of sugar beet.
Moreover, molasses is a valuable source of bioeth-anol, which meets all technical requirements of the motor fuel. Export of molasses for 2011 was twice increased, up to 290 thousand tons [4].
1 ton of conditional molasses (dry substances 85%) can give 310 - 315 dm3 of bioethanol [6]. In 2011 there was collected a record harvest of sugar beet (46.2 million tons) in Russia, and there was produced 1. 7 million tones of conditional molasses. Assuming that all of molasses will be used for biofuel production, its output will be: 1 700 000 x 310 = 527 thousand m3.
And this prospect remains unchanged, considering that in the following 2016 according to the Federal Service of State Statistics in all categories of farms there have been dug out 40.0 million tons of sugar beet. This is 24.4% higher than the previous year [3]. Meanwhile, it is claimed that by November 1, there have been harvested 83.5% of the areas of sugar beet.
If some improvements made in the technological line of the sugar factory, it is possible not to export molasses, but organize production of bioethanol in this country. To do this, a set of the standard process equipment and installation with molecular sieves for dehydration of alcohol should be purchased. The sugar plants already have TPP, water supply, workshops, transport, management personnel, as well as skilled workers. Processing molasses into bioethanol can be carried out in the off-season. Storage of molasses with minimal losses of sugar can be arranged [7].
Such organization of manufacturing can be cost-effective if the beet-sugar plant works according to the two-crystallization scheme, where the first and second edemas of massecuite II are put in the tank for short-term storage, and then are processed into ethanol under a simplified scheme with further dehydration to bioethanol [1].
The production cost of thus produced bioethanol is undoubtedly lower due to the exclusion of logistics operations at the organization of such manufacture on the ethanol plants.
Transport and wash sediments are formed in the amount of 5 % of the weight of the processed beet. The
by-product can be together with the filtration sludge dehydrated in the chamber filter-presses to moisture content of 30 % and be used as a cheap fertilizer.
Filtration sludge is about 10% of the number of processed raw materials at sugar plants. Less than 20% is used. The most popular way to use filtration sludge is neutralizing the acidity of the soil or it can be used as a limy fertilizer.
Due to the significant number of mineral substances, and primarily of calcium, filtration sludge can be used as mineral supplements for animals and birds.
Foreign countries practise processing of the filtration sludge into cement. Russian company "NT-Prom" proposed a similar project for the production of cement and concrete blocks of different geometry. A plant with the capacity of 120 thousand tons of cement per year is able to process 135 thousand tons of the filtration sludge for a year [2].
Thus, the profitability of sugar production can be increased along with the improvement of the ecological environment of the surrounding area by making specific efforts (mentioned above) and making minor (compared to the result obtained) investments in innovative science-intensive products.
References
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2. Cement production as an effective solution to environmental problems of processing of defecation // Engineering company «NT-Prom [web site]. URL: http://www.nt-prom.ru/Page176.html (date of access: 15.10.2012).
3. Data of the Federal Service of State Statistics on sugar beet harvesting in the Russian Federation as on November 1, 2016 // Sugur.ru [web site]. URL: http://sugar.ru/node/16749 (date of access: 11.22.2016).
4. In Russia there is produced 5 million tons of sugar // «Agronom» [agronomic portal]. URL: http://www.agronome.info/info/news/434 (date of access 13.10.2012).
5. Russia in 2012 may produce from 4.7 to 5.2 million tons of beet sugar // «Belarusian universal commodity exchange» [web site, 20.08.2012]. URL: http://secure.butb.by/index.php?page=64&id=31994 (date of access: 15.10.2012).
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8. Sunflower oil, cake, sunflower, fodder, bran. Market profile of 03.07.2012 // «Agroscan» [web site]. URL: http://agroscan.nichost.ru/rus/markets/agrar-ian/mixed_fodders_bran/ (date of access 13.10.2012)
